Method to enhance the durability of conductive carbon coating of pem fuel cell bipolar plates

ABSTRACT

A fuel cell component includes an electrode support material made with nanofiber materials of Titania and ionomer. A bipolar plate stainless steel substrate and a carbon-containing layer doped with a metal selected from the group consisting of platinum, iridium, ruthenium, gold, palladium, and combinations thereof.

BACKGROUND OF THE INVENTION

1. Field of the Invention

In at least one embodiment, the present invention is related to fuelcell components, and in particular, to flow field plates and catalystlayers in fuel cells.

2. Background Art

Fuel cells are used as an electrical power source in many applications.In particular, fuel cells are proposed for use in automobiles to replaceinternal combustion engines. A commonly used fuel cell design uses asolid polymer electrolyte (“SPE”) membrane or proton exchange membrane(“PEM”), to provide ion transport between the anode and cathode.

In proton exchange membrane type fuel cells, hydrogen is supplied to theanode as fuel and oxygen is supplied to the cathode as the oxidant. Theoxygen can either be in pure form (O₂) or air (a mixture of O₂ and N₂).PEM fuel cells typically have a membrane electrode assembly (“MEA”) inwhich a solid polymer membrane has an anode catalyst on one face, and acathode catalyst on the opposite face. The anode and cathode layers of atypical PEM fuel cell are formed of porous conductive materials, such aswoven graphite, graphitized sheets, or carbon paper to enable the fuelto disperse over the surface of the membrane facing the fuel supplyelectrode. Each electrode has finely divided catalyst particles (forexample, platinum particles), supported on carbon particles, to promoteoxidation of hydrogen at the anode and reduction of oxygen at thecathode. Protons flow from the anode through the ionically conductivepolymer membrane to the cathode where they combine with oxygen to formwater, which is discharged from the cell. The MEA is sandwiched betweena pair of porous gas diffusion layers (“GDL”), which in turn aresandwiched between a pair of non-porous, electrically conductiveelements or plates (i.e., flow field plates). The plates function ascurrent collectors for the anode and the cathode, and containappropriate channels and openings formed therein for distributing thefuel cell's gaseous reactants over the surface of respective anode andcathode catalysts. In order to produce electricity efficiently, thepolymer electrolyte membrane of a PEM fuel cell must be thin, chemicallystable, proton transmissive, non-electrically conductive and gasimpermeable. In typical applications, fuel cells are provided in arraysof many individual fuel cell stacks in order to provide high levels ofelectrical power.

The electrically conductive plates currently used in fuel cells providea number of opportunities for improving fuel cell performance. Forexample, these metallic plates typically include a passive oxide film ontheir surfaces requiring electrically conductive coatings to minimizethe contact resistance. Such electrically conductive coatings includegold and polymeric carbon coatings. Typically, these coatings requireexpensive equipment that adds to the cost of the finished bipolar plate.Moreover, metallic bipolar plates are also subjected to corrosion duringoperation. The degradation mechanism includes the release of fluorideions from the polymeric electrolyte. Metal dissolution of the bipolarplates typically results in release of iron, chromium and nickel ions invarious oxidation states.

Currently, the catalyst layers used in fuel cells are fabricated fromliquid compositions that include supported catalysts and ionomers.Although these methods work well, improvements are necessary because offabrication limitations imposed by using a liquid composition.Therefore, novel materials are desired for electrodes, which can be usedas support materials for catalysts that have high performance anddurability.

Accordingly, there is a need for improved methodology for lowering thecontact resistance at the surfaces of bipolar plates used in fuel cellapplications and for fabricating catalyst layers.

SUMMARY OF THE INVENTION

The present invention solves one or more problems of the prior art byproviding in at least one embodiment a fuel cell component. The fuelcell component includes a substrate and a carbon-containing layer dopedwith a metal selected from the group consisting of platinum, iridium,ruthenium, gold, palladium, and combinations thereof.Characteristically, the carbon containing layer has a ratio of sp² tosp³ hybridized carbon in the carbon-containing film from about 0.8 toabout 4. Advantageously, the carbon-containing layer exhibits improvedcorrosion resistance compared to carbon-containing layers that are dopedwith other metals such as titanium and chromium.

In another embodiment, a catalyst layer for fuel cell applications isprovided. The catalyst layer includes a carbon-containing compositionand an ionomeric composition. The carbon-containing composition is dopedwith a metal selected from the group consisting of platinum, iridium,ruthenium, gold, palladium, and combinations thereof.

In another embodiment, a catalyst support material is formulated. Thecatalyst support includes a mixed array of nanotubes of titania andionomeric material in defined compositions in intimate contact.

In still another embodiment, a flow field plate for fuel cellapplications is provided. The fuel cell plate includes a metal platehaving a first surface and a second surface. The first surface defines aplurality of channels for directing flow of a first gaseous composition.The flow field plate also includes a carbon-containing layer disposedover at least a portion of the metal plate. The carbon-containing layeris doped with a metal selected from the group consisting of platinum,iridium, ruthenium, gold, palladium, and combinations thereof. Moreover,the carbon containing layer has a ratio of sp² to sp³ hybridized carbonin the carbon-containing film from about 0.8 to about 4.

Other exemplary embodiments of the invention will become apparent fromthe detailed description provided hereinafter. It should be understoodthat the detailed description and specific examples, while disclosingexemplary embodiments of the invention, are intended for purposes ofillustration only and are not intended to limit the scope of theinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the present invention will become more fullyunderstood from the detailed description and the accompanying drawings,wherein:

FIG. 1 is a perspective view of a fuel cell incorporating the bipolarplates of an embodiment of the present invention;

FIG. 2A provides a cross-sectional view of a fuel cell incorporating anexemplary embodiment of a carbon-containing layer on a unipolar plate;

FIG. 2B provides a cross-sectional view of a fuel cell incorporating anexemplary embodiment of a carbon-containing layer on a bipolar plate;

FIG. 3 provides a cross-sectional view of a bipolar plate channel coatedwith a carbon-containing layer;

FIG. 4 provides a cross-sectional view of a fuel cell incorporatinganother exemplary embodiment of a carbon-containing layer on a bipolarplate;

FIG. 5 provides a schematic illustration of a carbon-containing layeruseful as a fuel cell catalyst;

FIG. 6 provides a flowchart illustrating an exemplary method for makinga bipolar plate coated with a carbon-containing layer; and

FIG. 7 is a schematic illustration of a sputtering system used todeposit carbon-containing layers.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

Reference will now be made in detail to presently preferredcompositions, embodiments and methods of the present invention, whichconstitute the best modes of practicing the invention presently known tothe inventors. The figures are not necessarily to scale. However, it isto be understood that the disclosed embodiments are merely exemplary ofthe invention that may be embodied in various and alternative forms.Therefore, specific details disclosed herein are not to be interpretedas limiting, but merely as a representative basis for any aspect of theinvention and/or as a representative basis for teaching one skilled inthe art to variously employ the present invention.

Except in the examples, or where otherwise expressly indicated, allnumerical quantities in this description indicating amounts of materialor conditions of reaction and/or use are to be understood as modified bythe word “about” in describing the broadest scope of the invention.Practice within the numerical limits stated is generally preferred.Also, unless expressly stated to the contrary: percent, “parts of,” andratio values are by weight; the term “polymer” includes “oligomer,”“copolymer,” “terpolymer,” and the like; the description of a group orclass of materials as suitable or preferred for a given purpose inconnection with the invention implies that mixtures of any two or moreof the members of the group or class are equally suitable or preferred;description of constituents in chemical terms refers to the constituentsat the time of addition to any combination specified in the description,and does not necessarily preclude chemical interactions among theconstituents of a mixture once mixed; the first definition of an acronymor other abbreviation applies to all subsequent uses herein of the sameabbreviation and applies mutatis mutandis to normal grammaticalvariations of the initially defined abbreviation; and, unless expresslystated to the contrary, measurement of a property is determined by thesame technique as previously or later referenced for the same property.

It is also to be understood that this invention is not limited to thespecific embodiments and methods described below, as specific componentsand/or conditions may, of course, vary. Furthermore, the terminologyused herein is used only for the purpose of describing particularembodiments of the present invention and is not intended to be limitingin any way.

It must also be noted that, as used in the specification and theappended claims, the singular form “a,” “an,” and “the” comprise pluralreferents unless the context clearly indicates otherwise. For example,reference to a component in the singular is intended to comprise aplurality of components.

Throughout this application where publications are referenced, thedisclosures of these publications in their entireties are herebyincorporated by reference into this application to more fully describethe state of the art to which this invention pertains.

The term “nanotubes” is used to define the tubes which are 20 to 500 nmin diameter and 50 to 1000 nm long.

The term titania nanotubes refers to nanotubes of titanium dioxide whichare 20 to 100 nm in diameter and 50 to 500 nm long.

The term Nafion nanotubes refers to nanotubes of Nafion which are 20 to500 nm in diameter and 50 to 1000 nm long.

The term “non-crystalline carbon layer” as used herein means a layercomprising at least 80 weight percent carbon with less than 10 weightpercent of the layer being crystalline. Typically, non-crystallinecarbon layers are at least 90 weight percent carbon with less than 5weight percent of the layer being crystalline. In a refinement,non-crystalline carbon layers are substantially amorphous carbon.

In an embodiment of the present invention, a carbon-containing layerthat is useful for fuel cell applications is provided. Thecarbon-containing layer is doped in order to increase the electricalconductivity. Specifically, the carbon-containing layer is doped withPt, Ir, Pd, Rh, Au, or Ru. 0.1 to 10 wt %. Advantageously, thecarbon-containing layer exhibits improved corrosion resistance comparedto carbon-containing layers that are doped with other metals such astitanium or chromium. In a variation, the carbon-containing layer ischaracterized by the ratio of sp² to sp³ hybridized carbon. In onerefinement, the ratio (i.e., molar ratio) of sp² to sp³ hybridizedcarbon in the carbon-containing film is from about 0.8 to about 4. Inanother refinement, the ratio of sp² to sp³ hybridized carbon in thecarbon-containing film is from about 1 to about 3. In still anotherrefinement, the ratio of sp² to sp³ hybridized carbon in thecarbon-containing film is from about 1.1[??] to about 2. The ratio ofsp² to sp³ carbon may be determined by a number of analytical techniquessuch as Raman Spectroscopy, C-13 NMR, and the like. In a furtherrefinement, the electrical conductivity of carbon-containing layer issuch that the contact resistance of fuel cell 10 is less than about 20mohm-cm².

In another embodiment of the present invention, a fuel cell componentcomprising an electrode having a non-carbon support material comprisingnanotubes of titania and an ion conducting ionomer is provided. Thenanotubes of titania are typically from about 20 to about 100 nm indiameter and from about 50 to about 500 nm in length. Similarly, thenanotubes of ion conducting ionomer are from about 20 to about 500 nm indiameter and from about 50 to about 1000 nm in length. In a variation ofthe present invention, the nanotubes of titania and ion conductingionomer are interdispersed. In a refinement, the nanotubes of titaniaand ion conducting ionomer are interdispersed with the amount of titaniananotubes being from about 30 to about 70% of the total number ofnanotubes. In another refinement, the nanotubes of titania and ionconducting ionomer are interdispersed with the amount of ion conductingnanotubes being from about 30 to about 70% of the total number ofnanotubes. Suitable ion conducting materials from which the ionconducting nanotubes are made include, but are not limited to, Nafionionomer, sulfonated polytrifluorostyrene, sulfonated hydrocarbonpolymer, polyimide, polyvinylidene fluoride, polybenzimidazole,polysulfone, polyethersulfone, polyetherketone, polyphenylenesulfide,polyphenyleneoxide, polyphosphazene, polyethylenenaphthalate, polyamide,polyester, and combinations thereof.

In a variation, Titania nanotubes are made by impregnating aluminatemplates that have columnar structure, with reactive organometallictitanium compounds such as titanium isopropoxide or ethoxide dissolvedin a solvent such as hexane. The solvent is allowed to dry out leavingbehind the reactive titanium compound inside the template, whichspontaneously reacts with water to yield titanium oxide which takes theshape of the template. The template is later removed using selectivedissolution of alumina in sodium hydroxide leaving behind Titaniananotubes. Nafion nanotubes are made using a similar process in which aNafion is used to impregnate the template. The Nafion will then beallowed to dry inside the template. Subsequently, the template isdissolved in sodium hydroxide or hydrofluoric acid leaving behind theNafion nanotubes.

In another variation, Titania or the Nafion are deposited inside thetemplates using plasma enhanced CVD process, magnetron sputterdeposition process, pulsed laser deposition process (PLD) or atomiclayer deposition (ALD) processes. Titanium precursors can be chosen frominorganic or organic titanium derivatives such as titaniumtetrachloride. Nafion is deposited from a 10% Nafion solution. Thetemperature regime in which the Ti nanotube growth is obtained is from100° C. to 450° C. The temperature range for preparing Nafion nanotubesis from 100 to 300° C. Plasma enhanced CVD will typically use amicrowave plasma source supply at 256 Hz. Ti nanotubes areadvantageously deposited from TiCl₄ precursor in the range of 350° C. to450° C.

The carbon-containing films of the present embodiment are advantageousused in a number of fuel cell components. With reference to FIG. 1, afuel cell comprising a metallic flow field plate is provided. Fuel cell10 includes flow field plates 12, 14. Flow field plate 12 includes aplurality of channels 16 for introducing a first gas into fuel cell 10.Typically, this first gas comprises oxygen. Diffusion layer 18 isdisposed over flow field plate 12. First catalyst layer 20 is disposedover diffusion layer 18. Fuel cell 10 further includes ion conductorlayer 22, which is disposed over first catalyst layer 20. Secondcatalyst layer 24 is disposed over ion conductor layer 22. Fuel cell 10also includes flow field plate 14 with gas diffusion layer 28 interposedbetween second catalyst layer 24 and flow field plate 14. Flow fieldplate 14 includes a plurality of channels 30. In a refinement, flowfield plates 12, 14 are made from a metal such as stainless steel. Inone variation, the carbon-containing films set forth above are coatedonto a surface of one or both of flow field plates 12, 14. In anotherrefinement, the carbon-containing films are incorporated into one orboth of first catalyst layer 20 and second catalyst layer 24.

In a variation of the present embodiment, ion conducting layer comprisesan ionomer. Suitable ionomers include, but are not limited to, Nafionionomer, sulfonated polytrifluorostyrene, sulfonated hydrocarbonpolymer, polyimide, polyvinylidene fluoride, polybenzimidazole,polysulfone, polyethersulfone, polyetherketone, polyphenylenesulfide,polyphenyleneoxide, polyphosphazene, polyethylenenaphthalate, polyamide,polyester, and combinations thereof. In a refinement, the ionomercomprises nanotubes or filaments.

Still referring to FIG. 1, the electrode having a non-carbon supportmaterial comprising nanotubes of titania and an ion conducting ionomermay be used for either or both of first catalyst layer 20 and/or secondcatalyst layer 24. Typically, this electrode contacts a substrate suchas ion conducting polymeric layer (e.g., ion conductor layer 22).

With reference to FIGS. 2A and 2B, schematic cross sections of fuelcells incorporating the flow field plates coated with thecarbon-containing films set forth above are provided. Fuel cell 40includes flow field plates 42, 44. Flow field plate 42 includes surface46 and surface 48. Surface 46 defines channels 50 and lands 52. FIG. 2Aprovides a depiction in which flow field plate 42 is a unipolar plateand flow field plate 44 is bipolar. FIG. 2B provides a depiction inwhich flow field plates 42, 44 are both bipolar plate. In thisvariation, surface 48 defines channels 54 and lands 56. Similarly, flowfield 44 includes surface 60 and surface 62. Surface 60 defines channels66 and lands 68. FIG. 2A provides a depiction in which flow field plate44 is a unipolar plate. FIG. 2B provides a depiction in which surface 62defines channels 70 and lands 72.

Still referring to FIGS. 2A and 2B, carbon-containing layer 80 isdisposed over and contacts surface 46. In a variation, carbon-containinglayer 80 includes surface 82 having a contact angle with water less thanabout 30 degrees. In one refinement, carbon-containing layer 80 has athickness from about 10-2000 nm

Still referring to FIGS. 2A and 2B, fuel cell 40 further includes gasdiffusion layer 90 and catalyst layers 92, 94. Polymeric ion conductivemembrane 100 is interposed between catalyst layers 92, 94. Finally, fuelcell 40 also includes gas diffusion layer 102 positioned betweencatalyst layer 94 and flow field plate 44.

In a variation of the present invention, a first gas is introduced intochannels 50 and a second gas is introduced into channels 66. Channels 50direct the flow of the first gas and channels 66 direct the flow of thesecond gas. In a typical fuel cell application, an oxygen-containing gasis introduced into channels 50 and a fuel is introduced into channels66. Examples of useful oxygen containing gases include molecular oxygen(e.g., air). Examples of useful fuels include, but are not limited to,hydrogen. When an oxygen-containing gas is introduced into channels 50,water is usually produced as a by-product which must be removed viachannels 50. In this variation, catalyst layer 92 is a cathode catalystlayer and catalyst layer 94 is an anode catalyst layer.

With reference to FIG. 3, a magnified cross-sectional view of channels50 is provided. Surfaces 110, 112, 114 of carbon-containing layer 80provide exposed surfaces in channels 50. Advantageously, these surfacesof carbon-containing layer 80 are hydrophilic, having a contact anglewith water less than about 30 degrees. In another refinement, thecontact angle is less than about 20 degrees. The hydrophilic nature ofcarbon-containing layer 80 prevents water from agglomerating in channels50.

In a variation of the present embodiment, the surface of thecarbon-containing film is activated by a plasma (e.g., RF plasma, DCplasma, microwave plasma, hot filament plasma, open air plasma, and thelike). In a refinement of the present embodiment, the hydrophilicity ofcarbon-containing layer 80 is improved by activating surface 82 of FIGS.2A and 2B (i.e., surfaces 110, 112, 114, 116). In one refinement, theactivation is accomplished by exposing the carbon-containing layers to areactive oxygen plasma which would activate the carbon-containing layersby breaking bonds and forming hydroxyl, carboxyl and aldehyde functionalgroups. In one refinement, the post treatment is accomplished byexposing the carbon-containing layers to reactive gases nitrogen,nitrous oxide, nitrogen dioxide, ammonia or mixture thereof, whichactivate the carbon-containing layers by breaking bonds and formingnitrogen-based derivatives like amines, amide, diazo functional groups.Accordingly, the post-treatment activation is able to increase theamounts of nitrogen and/or oxygen in carbon-containing layer 80. In afurther refinement, the amounts of nitrogen and oxygen are in regionswithin several nanometers of surface 82. In another refinement, theactivation of surface 82 results in an increase in porosity as comparedto the surface prior to activation. In a further refinement, surface 82includes regions in which there are at least 10 pores per m² of surfacearea. Moreover, surface 82 includes on average at least 5 pores permicron² of surface area. The number of pores per m² is calculated bycounting the number of pores in a given area observed in a scanningelectron micrograph.

With reference to FIG. 4, a schematic cross section illustratingadditional surfaces of fuel cell bipolar plates coated withcarbon-containing layers is provided. In this variation, one or more ofsurfaces 46, 48, 60, and 62 are coated with a carbon-containing layer.As set forth above, in connection with the description of FIGS. 2A and2B, fuel cell 40 includes flow field plates 42, 44. Bipolar plate 42includes surface 46 and surface 48. Surface 46 defines channels 50 andlands 52. Surface 48 defines channels 54 and lands 56. Similarly,bipolar plate 44 includes surface 60 and surface 62. Surface 60 defineschannels 66 and lands 68. Surface 62 defines channels 70 and lands 72.

Still referring to FIG. 4, carbon-containing layer 80 is disposed overand contacts surface 46. In a variation, carbon-containing layer 80includes surface 82 having a contact angle with water less than about 30degrees. Similarly, carbon-containing layer 120 is disposed over andcontacts surface 48, carbon-containing layer 122 is disposed over andcontacts surface 60, and carbon-containing layer 124 is disposed overand contacts surface 62. Fuel cell 40 further includes gas diffusionlayer 90 and catalyst layers 92, 94. Polymeric ion conductive membrane100 is interposed between catalyst layers 92, 94. Finally, fuel cell 40also includes gas diffusion layer 102 positioned between catalyst layer94 and bipolar plate 44. The details of carbon-containing layers 80,120, 122, 124 are set forth above in connection with the description ofFIGS. 2A and 2B.

In another embodiment of the present invention, a carbon-containinglayer useful as a fuel cell catalyst layer is provided. Thecarbon-containing layer includes a carbon-containing composition dopedwith an unreactive precious metal or platinum group metal (e.g., Pt, Ir,Pd, Au, or Ru). The carbon-containing layer also includes an ionconducting polymer (e.g., ionomer) to provide ion conductivity to thecarbon-containing layer. In a refinement, the ion conducting polymerincludes a component selected from the group consisting of Nafionionomer, sulfonated polytrifluorostyrene, sulfonated hydrocarbonpolymer, polyimide, polyvinylidene fluoride, polybenzimidazole,polysulfone, polyethersulfone, polyetherketone, polyphenylenesulfide,polyphenyleneoxide, polyphosphazene, polyethylenenaphthalate, polyamide,polyester, and combinations thereof. In another refinement, the ionconducting polymer comprises ionomeric nanotube or filament (e.g.,Nafion nanotubes or filaments).

With reference to FIG. 5, a schematic illustration of acarbon-containing layer useful as a fuel cell catalyst is provided.Carbon-containing layer 130 includes ionomeric regions 132 dispersedwithin carbon composition 134. Typically, carbon-containing layer 130 isfrom about 12 to about 25 microns. The ionomeric regions are typicallyabout 30 to about 50 wt % of the total weight of the ionomeric regions.In the variation depicted in FIG. 5, carbon-containing layer 130 coatssubstrate 136. In one refinement, substrate 136 is a gas diffusionlayer. In another refinement, substrate 136 is an ion conducting polymerlayer. In this embodiment, Nafion nanotubes are particularly useful forforming ionomeric regions 132 since they allow channels for ionconduction across carbon-containing layer 130. In another refinement,the ionomeric regions include hydrophobic and hydrophilic domains. Thesedomains occur in polymer such as Nafion which have a polymer backbonethat is hydrophobic and sulfonated side groups that are hydrophilic. Infuel cell applications, the hydrophobic regions tend to dominate atpositions closer to the polymeric ion conducting layer (e.g., membrane).

With reference to FIG. 6, a pictorial flowchart showing the preparationof the carbon-containing layer depicted in FIG. 5 is provided. Substrate136 is coated in step a) with first carbon-containing layer 140. Carboncontaining composition 134 is doped with a metal selected from thegroups consisting of platinum, iridium, ruthenium, gold, palladium, andcombinations thereof Typically, this carbon-containing composition isdeposited by a physical deposition technique such as sputtering. In stepb), ionomer layer 142 is coated onto first carbon-containing layer 140.In step c), ionomer layer 142 is hot pressed into firstcarbon-containing layer 140 to form carbon-containing layer 130 which isuseful as a fuel cell catalyst layer.

In a variation of the present embodiment, the carbon-containing layersset forth above are formed from carbon layers that are deposited bysputtering. In one refinement, the carbon layers are deposited using aclosed field unbalanced magnetron system. For this purpose, a variationof the method and apparatus is set forth in U.S. Pat. No. 6,726,993 (the'993 patent). The entire disclosure of the '993 patent is herebyincorporated by reference in its entirety.

With reference to FIG. 7, a refinement of a sputtering deposition systemfor depositing the carbon-containing layers set forth above is provided.A useful sputtering system is the Teer UDP 650 system. FIG. 7 provides aschematic top view of the sputtering system. Sputtering system 152includes deposition chamber 153 and sputtering targets 154, 156, 158,160 which are proximate to magnet sets 162, 164, 166, 168. A magneticfield generated between the targets 154, 156, 158, 160 is characterizedwith field lines extending between the magnetrons forming a closedfield. The closed field forms a barrier, which prevents the escape ofelectrons within plasma containing area 172. Moreover, thisconfiguration promotes ionization in the space within the closed fieldwith increased ion bombardment intensity. High ion current density isthereby achieved. Substrate 174 (i.e., metal plate 12) is held onplatform 176, which rotates along direction d₁. Flipper 182 causesrotation of substrate 174 about direction d₂ during a cycle of platform176. In one example, sputtering targets 154, 156 are carbon targetswhile sputtering targets 158, 160 optionally include the metal dopantsset forth above. Moreover, in this example, magnet sets 162, 164 providea more intense magnetic field than magnet sets 166, 168. This magneticimbalance allows for less dopant to be sputtered than carbon. Whensystem 152 is utilized, pre-conditioning step a) is advantageouslyperformed by ion etching within deposition chamber 153. In a refinement,the deposited carbon layer is removed by a plasma formed in depositionchamber 153.

While embodiments of the invention have been illustrated and described,it is not intended that these embodiments illustrate and describe allpossible forms of the invention. Rather, the words used in thespecification are words of description rather than limitation, and it isunderstood that various changes may be made without departing from thespirit and scope of the invention.

1. A fuel cell component comprising: an electrode having a non-carbonsupport material comprising nanotubes of titania and an ion conductingionomer. 2 The fuel cell component of claim 1 wherein the nanotubes oftitania are 20 to 100 nm in diameter and 50 to 500 nm in length.
 3. Thefuel cell component of claim 1 wherein the nanotubes of Nafion ionomerare 20 to 500 nm in diameter and 50 to 1000 nm in length.
 4. The fuelcell component of claim 1 wherein the nanotubes of titania and Nafionionomer are interdispersed.
 5. The fuel cell component of claim 1wherein the nanotubes of titania and Nafion ionomer are interdispersed,the nanotubes comprising from about 20 to about 70% titania nanotubes. 6The fuel cell component of claim 1 wherein the nanotubes of titania andNafion ionomer are interdispersed, the nanotubes comprising from about20 to about 70% Nafion nanotubes.
 7. The fuel cell component of claim 1wherein the nanotubes of titania and Nafion ionomer contact a substrate.8 The fuel cell component of claim 7 wherein the substrate is an ionconducting polymeric layer.
 9. The fuel cell component of claim 1wherein the ionomer comprises a component selected from the groupconsisting of Nafion ionomer, sulfonated polytrifluorostyrene,sulfonated hydrocarbon polymer, polyimide, polyvinylidene fluoride,polybenzimidazole, polysulfone, polyethersulfone, polyetherketone,polyphenylenesulfide, polyphenyleneoxide, polyphosphazene,polyethylenenaphthalate, polyamide, polyester, and combinations thereof.10. A fuel cell component comprising: a substrate; and acarbon-containing layer disposed over the substrate, thecarbon-containing layer being doped with a metal selected from the groupconsisting of platinum, iridium, ruthenium, gold, palladium, andcombinations thereof, the carbon containing layer having a ratio of sp²to sp³ hybridized carbon from about 0.8 to about
 4. 11. The fuel cellcomponent of claim 10 wherein the carbon-containing layer has a surfacewith a contact angle with water less than about 30 degrees.
 12. The fuelcell component of claim 10 wherein the contact angle is less than 20degrees.
 13. The fuel cell component of claim 10 wherein the substratehas an ionic conducting polymeric layer and the fuel cell component is acatalyst layer.
 14. The fuel cell component of claim 13 wherein thecarbon-containing layer further comprises an ionomer.
 15. The fuel cellcomponent of claim 14 wherein the ionomer comprises a component selectedfrom the group consisting of Nafion ionomer, sulfonatedpolytrifluorostyrene, sulfonated hydrocarbon polymer, polyimide,polyvinylidene fluoride, polybenzimidazole, polysulfone,polyethersulfone, polyetherketone, polyphenylenesulfide,polyphenyleneoxide, polyphosphazene, polyethylenenaphthalate, polyamide,polyester, and combinations thereof.
 16. The fuel cell component ofclaim 10 wherein the ionomer comprises Nafion nanotubes or filaments.17. A catalyst layer for a fuel cell, the catalyst layer comprising: acarbon-containing composition doped with a metal selected from the groupconsisting of platinum, iridium, ruthenium, gold, palladium, andcombinations thereof, and an ionomeric composition.
 18. The catalystlayer of claim 17 wherein the ionomer composition comprises a componentselected from the group consisting of Nafion ionomer, sulfonatedpolytrifluorostyrene, sulfonated hydrocarbon polymer, polyimide,polyvinylidene fluoride, polybenzimidazole, polysulfone,polyethersulfone, polyetherketone, polyphenylenesulfide,polyphenyleneoxide, polyphosphazene, polyethylenenaphthalate, polyamide,polyester, and combinations thereof.
 19. The catalyst layer of claim 17wherein the ionomeric composition comprises Nafion nanotubes orfilaments.
 20. The catalyst layer of claim 17 wherein the carboncontaining composition has a ratio of sp² to sp³ hybridized carbon fromabout 0.8 to about
 4. 21. The catalyst layer of claim 17 wherein theionomeric composition includes hydrophobic domains and hydrophilicdomains.
 22. The catalyst layer of claim 17 wherein the ionomer ispresent in an amount from about 30-50 wt %.
 23. A flow field plate forfuel cell applications comprising: a metal plate having a first surfaceand a second surface, the first surface defining a plurality of channelsfor directing flow of a first gaseous composition; and acarbon-containing layer disposed over at least a portion of the metalplate, the carbon-containing layer doped with a metal selected from thegroup consisting of platinum, iridium, ruthenium, gold, palladium, andcombinations thereof, the carbon containing layer having a ratio of sp²to sp³ hybridized carbon from about 0.8 to about
 4. 24. The flow fieldplate of claim 23 wherein the carbon-containing layer has a surface witha contact angle with water less than about 30 degrees.
 25. The flowfield plate of claim 24 wherein the contact angle is less than 20degrees.
 26. A cathode flow field plate comprising the flow field plateof claim 23.